Abstract

The Salt Disposition Integration (SDI) portfolio of projects provides the infrastructure within existing Liquid Waste facilities to support the startup and long term operation of the Salt Waste Processing Facility (SWPF). Within SDI, the Blend and Feed Project will equip existing waste tanks in the Tank Farms to serve as Blend Tanks where 300,000-800,000 gallons of salt solution will be blended in 1.3 million gallon tanks and qualified for use as feedstock for SWPF. Blending requires the miscible salt solutions from potentially multiple source tanks per batch to be well mixed without disturbing settled sludge solids that may be present in a Blend Tank. Disturbing solids may be problematic both from a feed quality perspective as well as from a process safety perspective where hydrogen release from the sludge is a potential flammability concern. To develop the necessary technical basis for the design and operation of blending equipment, Savannah River National Laboratory (SRNL) completed scaled blending and transfer pump tests and computational fluid dynamics (CFD) modeling. A 94 inch diameter pilot-scale blending tank, including tank internals such as the blending pump, transfer pump, removable cooling coils, and center column, were used in this research. The test tank represents a 1/10.85 scaled version of an 85 foot diameter, Type IIIA, nuclear waste tank that may be typical of Blend Tanks used in SDI. Specifically, Tank 50 was selected as the tank to be modeled per the SRR, Project Engineering Manager. SRNL blending tests investigated various fixed position, non-rotating, dual nozzle pump designs, including a blending pump model provided by the blend pump vendor, Curtiss Wright (CW). Primary research goals were to assess blending times and to evaluate incipient sludge disturbance for waste tanks. Incipient sludge disturbance was defined by SRR and SRNL as minor blending of settled sludge from the tank bottom into suspension due to blending pump operation, where the sludge level was shown to remain constant. To experimentally model the sludge layer, a very thin, pourable, sludge simulant was conservatively used for all testing. To experimentally model the liquid, supernate layer above the sludge in waste tanks, two salt solution simulants were used, which provided a bounding range of supernate properties. One solution was water (H{sub 2}O + NaOH), and the other was an inhibited, more viscous salt solution. The research performed and data obtained significantly advances the understanding of fluid mechanics, mixing theory and CFD modeling for nuclear waste tanks by benchmarking CFD results to actual experimental data. This research significantly bridges the gap between previous CFD models and actual field experiences in real waste tanks. A finding of the 2009, DOE, Slurry Retrieval, Pipeline Transport and Plugging, and Mixing Workshop was that CFD models were inadequate to assess blending processes in nuclear waste tanks. One recommendation from that Workshop was that a validation, or bench marking program be performed for CFD modeling versus experiment. This research provided experimental data to validate and correct CFD models as they apply to mixing and blending in nuclear waste tanks. Extensive SDI research was a significant step toward bench marking and applying CFD modeling. This research showed that CFD models not only agreed with experiment, but demonstrated that the large variance in actual experimental data accounts for misunderstood discrepancies between CFD models and experiments. Having documented this finding, SRNL was able to provide correction factors to be used with CFD models to statistically bound full scale CFD results. Through the use of pilot scale tests performed for both types of pumps and available engineering literature, SRNL demonstrated how to effectively apply CFD results to salt batch mixing in full scale waste tanks. In other words, CFD models were in error prior to development of experimental correction factors determined during this research, which provided a technique to use CFD models for salt batch mixing and transfer pump operations. This major scientific advance in mixing technology resulted in multi-million dollar cost savings to SRR. New techniques were developed for both experiment and analysis to complete this research. Supporting this success, research findings are summarized in the Conclusions section of this report, and technical recommendations for design and operation are included in this section of the report. Document type: Report

Abstract

Based on earlier hydrotransport research by English and Russian researchers, a special test stand has been designed and constructed to obtain data to determine hydraulic drag, pipe wear, and comminution of particles. These data are intended for design and separate-effects operating information. This information will be used to supplement data developed by the Hydrotransport Research Facility located at the Pittsburgh Mining Operations, Pittsburgh, Pennsylvania. This report describes the equipment as designed, explains how the hydraulic drag is calculated using test-stand data, and presents some preliminary tests results using water. Tests using water are continuing to further substantiate the system and later, tests will be started using slurries. Document type: Report

Abstract

Millions of gallons of radioactive liquid and sludge wastes must be retrieved from underground storage tanks at the U.S. Department of Energy sites to be staged and transferred to treatment facilities and processed into final waste forms. Retrieval operations involve mixing solid and liquid wastes to create slurries that can be transported via underground pipelines to specified locations for treatment or disposal. A major concern during the transfer operations is plugging of the transfer lines. Blocked transfer lines could significantly escalate the remediation costs both in terms of pipeline replacement costs and costs of maintenance of inactive facilities and operating personnel. Document type: Report

Abstract

This report is a collection of summary articles on FY 2000 studies of slurry transport and salt-well pumping related to Hanford tank waste transfers. These studies are concerned with the stability (steady, uninterrupted flow) of tank waste transfers, a subset of the Department of Energy (DOE) Tanks Focus Area Tank (TFA) Waste Chemistry effort. This work is a collaborative effort of AEA Technology plc, the Diagnostic Instrumentation and Analysis Laboratory at Mississippi State University (DIAL-MSU), the Hemispheric Center for Environmental Technology at Florida International University (HCET-FIU), Numatec Hanford Corporation (NHC), and the Oak Ridge National Laboratory (ORNL). The purpose of this report is to provide, in a single document, an overview of these studies to help the reader identify contacts and resources for obtaining more detailed information and to help promote useful interchanges between researchers and users. Despite over 50 years of experience in transporting radioactive tank wastes to and from equipment and tanks at the Department of Energy's Hanford, Savannah River, and Oak Ridge sites, waste slurry transfer pipelines and process piping become plugged on occasion. At Hanford, several tank farm pipelines are no longer in service because of plugs. At Savannah River, solid deposits in the outlet line of the 2H evaporator have resulted in an unplanned extended downtime. Although waste transfer criteria and guidelines intended to prevent pipeline plugging are in place, they are not always adequate. To avoid pipeline plugging in the future, other factors that are not currently embodied in the transfer criteria may need to be considered. The work summarized here is being conducted to develop a better understanding of the chemical and waste flow dynamics during waste transfer. The goal is to eliminate pipeline plugs by improving analysis and engineering tools in the field that incorporate this understanding. Document type: Report

Abstract

This project, which began in FY97, involves both the flow loop research on plugging and unplugging of waste transfer pipelines, and the large-scale industrial equipment test of plugging locating and unplugging technologies. In FY98, the related work was performed under the project name ''Mixing, Settling, and Pipe Unplugging of Waste Transfer Lines.'' The mixing, settling, and pipeline plugging and unplugging are critical to the design and maintenance of a waste transfer pipeline system, especially for the High-Level Waste (HLW) pipeline transfer. The major objective of this work is to recreate pipeline plugging conditions for equipment testing of plug locating and removal and to provide systematic operating data for modification of equipment design and enhancement of performance of waste transfer lines used at DOE sites. As the waste tank clean-out and decommissioning program becomes active at the DOE sites, there is an increasing potential that the waste slurry transfer lines will become plugged and unable to transport waste slurry from one tank to another or from the mixing tank to processing facilities. Transfer systems may potentially become plugged if the solids concentration of the material being transferred increases beyond the capability of the prime mover or if upstream mixing is inadequately performed. Plugging can occur due to the solids' settling in either the mixing tank, the pumping system, or the transfer lines. In order to enhance and optimize the slurry's removal and transfer, refined and reliable data on the mixing, sampling, and pipe unplugging systems must be obtained based on both laboratory-scale and simulated in-situ operating conditions. Document type: Report

Abstract

This report presents the methods and results of calculations performed to predict the critical velocity and pressure drop required for the two-inch pipeline transfer of solid/liquid waste slurry from underground waste storage Tank 241-SY-101 to Tank 241-SY- 102 at the Hanford Site. The effects of temperature and dilution on the critical velocity were included in the analysis. These analyses show that Tank 241-SY-101 slurry should be diluted with water prior to delivery to Tank 241-SY-102. A dilution ratio of 1:1 is desirable and would allow the waste to be delivered at a critical velocity of 1.5 ft/sec. The system will be operated at a flow velocity of 6 ft/sec or greater therefore, this velocity will be sufficient to maintain a stable slurry delivery through the pipeline. The effect of temperature on the critical velocity is not a limiting factor when the slurry is diluted 1:1 with water. Pressure drop at the critical velocity would be approximately two feet for a 125-ft pipeline (or 250-ft equivalent straight pipeline). At 6 ft/sec, the pressure drop would be 20 feet over a 250-ft equivalent straight pipeline. Document type: Report

Abstract

The External Flowsheet Review Team (EFRT) has identified the issues relating to the Waste Treatment and Immobilization Plant (WTP) pipe plugging. Per the review’s executive summary, “Piping that transports slurries will plug unless it is properly designed to minimize this risk. This design approach has not been followed consistently, which will lead to frequent shutdowns due to line plugging.” To evaluate the potential for plugging, testing was performed to determine critical velocities for the complex WTP piping layout. Critical velocity is defined as the point at which a moving bed of particles begins to form on the pipe bottom during slurry-transport operations. Pressure drops across the fittings of the test pipeline were measured with differential pressure transducers, from which the critical velocities were determined. A WTP prototype flush system was installed and tested upon the completion of the pressure-drop measurements. We also provide the data for the overflow relief system represented by a WTP complex piping geometry with a non-Newtonian slurry. A waste simulant composed of alumina (nominally 50 ?m in diameter) suspended in a kaolin clay slurry was used for this testing. The target composition of the simulant was 10 vol% alumina in a suspending medium with a yieldmore » stress of 3 Pa. No publications or reports are available to confirm the critical velocities for the complex geometry evaluated in this testing; therefore, for this assessment, the results were compared to those reported by Poloski et al. (2008) for which testing was performed for a straight horizontal pipe. The results of the flush test are compared to the WTP design guide 24590-WTP-GPG-M-0058, Rev. 0 (Hall 2006) in an effort to confirm flushing-velocity requirements.« le Document type: Report

Abstract

Despite over 50 years of experience in transporting radioactive tank wastes to and from equipment and tanks at the Department of Energy's Hanford, Savannah River, and Oak Ridge sites, waste slurry transfer pipelines and process piping become plugged on occasion. At Hanford, several tank farm pipelines are no longer in service because of plugs. At Savannah River, solid deposits in the outlet line of the 2H evaporator have resulted in an unplanned extended downtime. Although waste transfer criteria and guidelines intended to prevent pipeline plugging are in place, they are not always adequate. To avoid pipeline plugging in the future, other factors that are not currently embodied in the transfer criteria may need to be considered. The work summarized here is being conducted to develop a better understanding of the chemical and waste flow dynamics during waste transfer. The goal is to eliminate pipeline plugs by improving analysis and engineering tools in the field that incorporate this understanding. Document type: Report

Abstract

This study assesses five steps for Tank 241-AN-105 waste retrieval and subsequent pipeline transfer: 1. Remove supernatant liquid waste from AN-105 and transfer it through a pipeline with inline dilution with water (1st liquid waste transfer). 2. Add water (as a diluent) to Tank AN-105. 3. Mix the saltcake waste and water with mixer pumps to dissolve soluble solids. 4. Let undissolved solids settle to the tank bottom. 5. Remove the resulting supernatant liquid waste from Tank AN-105 (2nd liquid waste transfer). To assess these five steps for waste retrieval and pipeline transfer, AN-105 waste rheology was measured and solids identified with bright field image, select area diffraction, and energy dispersive x-ray spectroscopy. By combining available in situ and laboratory data, an AN-105 specific viscosity model was developed that can change from several centiPoise of viscosity to tens of millions of centiPoise as a function of strain rate and solid concentration. This viscosity mo del was implemented into the AN-105 computer model to simulate pump jet mixing. The report also evaluates AN-105 slurry waste transfer to AP-102 and AP-104 through a 3-inch (0.07-m) pipeline. Document type: Report